WO2018067164A1 - Moulage par injection à plusieurs entrées - Google Patents

Moulage par injection à plusieurs entrées Download PDF

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Publication number
WO2018067164A1
WO2018067164A1 PCT/US2016/055875 US2016055875W WO2018067164A1 WO 2018067164 A1 WO2018067164 A1 WO 2018067164A1 US 2016055875 W US2016055875 W US 2016055875W WO 2018067164 A1 WO2018067164 A1 WO 2018067164A1
Authority
WO
WIPO (PCT)
Prior art keywords
injection
mold cavity
mold
gates
metal substrate
Prior art date
Application number
PCT/US2016/055875
Other languages
English (en)
Inventor
Chien-Chih Chiu
Ya-Ting Yeh
Ken Tsai
Guess WEI
Original Assignee
Hewlett-Packard Development Company, L.P.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Hewlett-Packard Development Company, L.P. filed Critical Hewlett-Packard Development Company, L.P.
Priority to PCT/US2016/055875 priority Critical patent/WO2018067164A1/fr
Publication of WO2018067164A1 publication Critical patent/WO2018067164A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C2045/279—Controlling the flow of material of two or more nozzles or gates to a single mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/2701—Details not specific to hot or cold runner channels
    • B29C45/2708—Gates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/34—Moulds having venting means

Definitions

  • Injection molding as a manufacturing process may be used for molding plastic structures on a metal substrate which then may be used in a wide variety of components such as electronic device enclosures, automobile instrument panels, household machines, industrial machines and the like. Injection molding, generally, involves injecting a mokJable plastic material over a metal substrate which may be placed in a mold cavity. As the plastic material cools, it hardens and assumes the configuration and shape of the mold cavity.
  • FIG. 1 illustrates an example injection mold having at least three injection gates
  • FIG. 2 illustrates another example injection mold having multiple injection gates
  • FIG. 3 illustrates yet another example injection mold having air vents on at least two opposite walls
  • FIG. 4 illustrates a method for injection molding process implemented on an example injection mold.
  • PMH based injection molding techniques may include forming an article, or a part thereof, by bonding plastic to metal.
  • plastic structures such as mounting bosses, snap fits, reinforcement ribs, and the like, may be directly formed on a surface of the metal. In this way, an end product is a single article formed integrally constituting both plastic and metal.
  • NMT nanc-molding technology
  • An example of such PMH based injection molding technology is nanc-molding technology (NMT).
  • NMT provides for bonding and molding a plastic structure onto a metal substrate.
  • an NMT process involves multiple stages of pre -treatment of a bare metal substrate. The p re- treatment is carried out for removal of unwanted grease, oil, oxides, or other impurities, from the metal substrate.
  • the metal substrate may be submerged into an anodizing agent to form irregularities, such as nano-pores, on exterior surface. Thereafter, the anodized metal substrate is rinsed in water.
  • the metal substrate may be inserted into a mold cavity of a mold, wherein a moldable plastic material, such as material formed from molten plastic resin pellets, is injected to form a structure or shape directly on the exterior surface of the metal substrate.
  • a moldable plastic material such as material formed from molten plastic resin pellets
  • NMT is suitable for many applications
  • NMT involves the usage of hazardous chemicals, such as acids, for pre-treatment and anodizing of the metal substrate.
  • acids such as acids
  • Such acids if not removed properly, may create issues, such as formation of void gaps or air bubbles, between the moldable plastic material and the metal substrate.
  • issues may affect the strength of plastic-to-metal bond, thereby limiting use of NMT to selected few applications.
  • the mold may have only one point through which a moldable plastic material may be injected over the surface of the metal substrate.
  • the moldable plastic material when inserted may not uniformly advance within the mold cavity of the mold.
  • the proportion of the plastic material may be less. It may happen because pressure applied for injecting the moldable plastic material from a single entry may not be sufficient for the moldable plastic material to completely reach the furthermost spaces situated away from the single injection point.
  • Such a non-uniform distribution results in improper gaps between the moldable plastic material and the metal substrate. With such improper gaps, the plastic-to-metal bond achieved by the NMT has a relatively short shelf-life with the adhesion strength diminishing after some time period.
  • the injection mold may include a mold cavity.
  • the mold cavity may enclose a volume which is larger than a volume required for accommodating a metal substrate during injection molding of a structure.
  • the metal substrate may be a stamped sheet metal substrate having a nano-porous layer on its exterior surface.
  • the injection mold may further include at least three injection gates formed in an upper surface of the mold cavity.
  • the three injection gates may be formed on the mold cavity at specific distances from each other.
  • the number of injection gates is at least three, but may range between 4 and 6 in numbers.
  • the number of injection gates may be selected based on length of the plastic structure that would be formed on the metal substrate.
  • a moldable plastic material which may be formed from molten plastic resin pellets, is injected through the injection gates on the injection mould.
  • the injection gates are uniformly situated across the dimensions of the mold cavity.
  • the moldable plastic material is injected through the three respective injection points into the mold cavity.
  • the moldable plastic material occupies the vacant space between the inner walls of the mold cavity and the metal substrate, to form a structure onto the metal substrate.
  • the moldable plastic material uniformly advances within the mold cavity resulting into a uniform distribution of the moldable plastic material onto the entire surface of the metal substrate.
  • the moldable plastic material is injected through a larger number of injection gates, the moldable plastic material is able to reach the farthermost spaces and uniformly occupy the spacing between the inner walls of the mold cavity and the metal substrate. This reduces irregular gaps between the moldable plastic material and the metal substrate, and further enables formation of a strong mechanical bond between the moldable plastic material and the metal substrate.
  • FIG. 1 illustrates an example of an injection mold 102.
  • the injection mold 102 may include a body 104 having a mold cavity 106 formed therein.
  • the mold cavity 106 defines a volume.
  • the volume enclosed within the mold cavity 106 such that a portion of the volume is sufficient to accommodate a metal substrate (not shown in FIG. 1) during injection molding process.
  • the metal substrate can be formed from materials including, but not limited to, aluminium, 5052 aluminium, aluminium alloy, titanium, titanium alloy, magnesium, and/or magnesium alloy.
  • the injection mold 102 further includes at least three injection gates 108-1, 2, 3 N, collectively referred to as gates 108. It should be noted that in the present description, a reference to injection gates 108 implies at least three injection gates 108.
  • the injection gates 108 may be formed on an upper surface of the mold cavity 106, with one side opening into, and fluidly connected with an inner surface of the mold cavity 106. The other end of the injection gates 108 is in communication with channels (not shown in FIG. 1) for receiving and feeding a moldable plastic material.
  • the moldable plastic material can be molten plastic resin pallets selected, without limitation, from the group consisting of polyamide, polycarbonate, acrylonitrile butadiene styrene copolymer, polypheny! sulfide, polypropylene, polybutylene terephthalate, and polyethylene terephthalate.
  • the moldable plastic material can be a thermoplastic and/or an injection moldable thermosetting plastic.
  • the injection gates 108 may be opened or closed to control the flow of the moldable plastic material there through.
  • Each of the injections gates 108 may be opened or closed either independently from each other, or in conjunction with each other during a single injection molding cycle.
  • An injection molding cycle may be considered as a sequence of processes are performed for injection molding of a single structure on a metal substrate.
  • the injection gates 108 may be opened by a pressure applied by the moldable plastic material received from the channels. When opened, the injection gates 108 may permit the injection of the moldable plastic material at three respective injection points into the mold cavity 106. As would be understood the different injection gates 108 are distributed across the injection mold 102 to uniformly distribute the injected moldable plastic material over the entire surface of metal substrate. As a result, the moldable plastic material is able to reach the farthermost spaces from the injection gates 108. Since the moldable plastic material is uniformly distributed and formed over the entire surface of the metal substrate, the instances of irregular gaps forming between the moldable plastic material and the metal substrate are also less. Thereby, a strong mechanical bond between the moldable material and the metal substrate is formed.
  • FIG. 2 illustrates another example of the injection mold 102.
  • the injection mold 102 may include a multipart body 202.
  • the multi-part body 202 may include a fixed portion 204 and removable portion 206 with a mold cavity 106 formed there between.
  • the mold cavity 106 encloses a volume, a portion of which is used for accommodating metal substrate 208.
  • the inner surface of the mold cavity 106 further defines the shape corresponding to a portion of an outer surface to a structure that is to be formed, on the metal substrate 208, within the mold cavity 106.
  • the removable portion 206 may include runner system.
  • the runner system may be considered as channels or openings for receiving the mokJable plastic material, at high pressure and temperature from an injection nozzle of an injection moulding machine (not shown in figures).
  • the runner system may include a sprue 210 and channels or runners 212 connected to the sprue 210.
  • the sprue 210 receives the moldable plastic material from the injection nozzle, which is then introduced into the runners 212.
  • the runners 212 may include a series of locations and pathways which are in fluid communication with the sprue 210.
  • the runners 212 form pathways through which the moldable plastic material flows towards the mold cavity 106.
  • the runner system may be formed on a metallic insert which is then placed above the injection mold 102 designed with single-part body.
  • the replaceable portion 204 may further include a series of injection gates
  • the injection gates 108 may be formed in such a way that the one side of the injection gates 108 communicates with the respective runners 212 and the other side of the injection gates 108 is in fluid communication with the inner surface of the mold cavity 106.
  • the injection gates 108 may be formed as gate valves.
  • Each of the gate valves may include a valve housing having passageways therein for receiving the moldable plastic material from the respective runners 212.
  • each of gate valves may include a cylindrical gate of restricted dimensions adapted to communicate with an orifice formed on the upper surface of the mold cavity 106, for injecting a jet of the moldable plastic material under a predetermined pressure into the mold cavity 106. Such jet of the moldable plastic material may then advance over entire inner surface, including walls and comers, of the mold cavity 106, and flow around the mold cavity 106 to fill therein.
  • the dimensions of the cylindrical gate can be varied using a control system (not shown in FIG.2).
  • the control system may include one of a mechanical control system and an electronic control system.
  • the number of injection gates 108 is at least three, but may range between 4 and 6 in numbers.
  • the number of injection gates 108 may correspond to the length of the structure, say plastic structure, that would be formed on the metal substrate 208.
  • the number of injection gates 108 may be also based on appearance, deformation, molding constringency rate, and strength of articles molded in the injection mold 102.
  • the injection mold 102 described herein may be able to fill distant spaces, such as corners in the mold cavity 106 with the moldable plastic material in a minimum possible time. This, in turn, improves the molding stage yield rate of the injection molding process.
  • the series of the injection gates 108 may allow the injection of the moldable plastic material at different equidistant injection points into the mold cavity 106. With such injection, the moldable plastic material evenly flows into the entire mold cavity 106. As a result, the moldable plastic material is able to reach farthermost points over the metal substrate 208. Since the farthermost points are still close as compared to the instances when injection was carried out with one single gate, the irregular gaps between the moldable plastic material and the metal substrate 208 are reduced. This, in turn, enables formation of a strong mechanical bond between the moldable plastic material and the metal substrate 208.
  • the mold cavity 106 formed inside the injection mold 102 may be pre-processed before molding stage.
  • the mold cavity 106 may be pre-processed with a smooth or textured finish in order to impart a smooth or textured finish on the metal substrate 208 during the molding stage.
  • the mold cavity 106 receives the metal substrate 208 in a portion of its volume.
  • the pressure retention stage involves maintaining a specified pressure applied to the injected moldable plastic material so as to compensate shrinkage of the plastic material injected, into the mold cavity 106 which may occure due to a natural fall in temperature.
  • the injection mold 102 may include a plurality of air vents 302-1, 2 N, collectively referred to as air vents 302.
  • the air vents 302 may be provided on at least two opposite walls of the mold cavity 106 and with a prescribed width. In one example, the prescribed width is about 0.15 mm. With such configuration of the air vents 302 in the mold cavity 106, the specified pressure can be easily maintained on to the injected moldable plastic material.
  • the air vents 302 included in the mold cavity 106 may be used for expulsion of residuals of the chemicals, such as acids, along with the air from the mold cavity 106.
  • the air vents 302 thus facilitates removal of residuals of the acids, which otherwise may involve complex pre-treatment of the mold cavity 106. This, in turn, enhances the yield rate of the injection molding process, as the described air vents 302 can potentially lower the number of injection mold stages by eliminating the involvement of pre-treatment of the mold cavity 106 for acid related issues.
  • the metal substrate 208 reduces the issues, such as void gaps or air bubbles, between the metal substrate 208 and the structure formed on the metal substrate 208, as the acids are suitably removed from the mold cavity 106 before initiation of the molding stage. Furthermore, the reduction of the acid related issues may help to prevent partial filling of nano-pores formed on the external surface of the metal substrate 208 or the mold cavity 106, and prevent various other defects in a product that would be formed.
  • a cooling stage may be initiated in which the removable portion 206 of the injection mold 102 is separated from the fixed portion 204 after the mold cavity 106 is completed filled with the moldable plastic material and the moldable plastic material is allowed to cool.
  • the injection mold 102 may include a plurality cooling channels (not shown in figures) formed in the fixed portion 204.
  • the plurality cooling channels can allow a liquid coolant to flow through the fixed portion 204 to conduct heat away from the mold cavity 106.
  • the molded article may include the metal substrate 208 and the structure formed on the metal substrate 208.
  • the metal substrate 208 may be a thin-walled structure and the structure formed on the metal substrate 208 may be a stiffener operative to rigidity the thin walled structure.
  • FIG. 4 illustrates a method 400 for carrying out injection molding process, according to an example of the present subject matter.
  • the method 400 is implemented in an injection molding device, such as the injection mold 102.
  • the order in which the method 400 is described is not intended to be construed as a limitation, and any number of the described method blocks can be combined in any order to implement the method 400, or alternative method.
  • the method 400 can be implemented in any suitable devices having applicability in the fields of PMH) injection molding technologies.
  • the method includes positioning a metal substrate 208 in the mold cavity 106 of the injection mold 102.
  • the mold cavity 106 may include a volume having a portion for accommodating the metal substrate 208, during an injection molding of a structure, say, plastic structure, on the metal substrate 208.
  • the volume of the mold cavity 106 is such that a portion of the volume is sufficient to accommodate the metal substrate.
  • the metal substrate may be a stamped sheet metal substrate having a nano-porous layer on its exterior surface.
  • the injection mold 102 may further include channels or runners 212.
  • the runners 212 may include a series of pathways through which the moldable plastic material flows within the mold cavity 106.
  • the moldable plastic material can be molten plastic resin pallets selected, without limitation, from the group consisting of polyamide, polycarbonate, acrylonitrile butadiene styrene copolymer, polypheny! sulfide, polypropylene, polybutylene terephthalate, and polyethylene terephthalate.
  • the moldable plastic material can be a thermoplastic and/or an injection moldable thermosetting plastic.
  • the injection mold may further include at least three injection gates 108 formed in an upper surface of the mold cavity 106.
  • the injection gates 108 may be formed in such a way that one side of the injection gates 108 communicates with the respective runners 212 and the other side of the injection gates 108 is in fluid communication with the inner surface of the mold cavity 106.
  • the method includes injecting a moldable plastic material through the at least three injection gates 108 into the mold cavity 106 to form the structure, say, plastic structure, on the exterior surfaces of the metal substrate 208.
  • the injecting may be performed by over-molding the moldable plastic material with the at least three injection gates 108 over the nano-pores formed on the exterior surface of the metal substrate 208.
  • the mokJable plastic material is injected at multiple injection points on the external surface of the metal substrate 208.
  • the mokJable plastic material is uniformly distributed on each of the nano-pores present on the exterior surface of the metal substrate 208.
  • the mokJable plastic material is able to reach and penetrate all the nano-pores, which are even farthermost nano-pores from the at least three injection gates 108. Since all the nano-pores are filled by the at least three injection gates 108, the irregular gaps between the mokJable plastic material and metal substrate 208 are reduced. This, in turn, provides a strong mechanical bond between the mokJable plastic material and the metal substrate 208.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

Un exemple l'invention concerne un moule d'injection. Selon un exemple, le moule d'injection peut comprendre une cavité de moule ayant une partie destinée à recevoir un substrat métallique. Le moule d'injection peut en outre comprendre au moins trois entrées d'injection formées dans une surface supérieure de la cavité de moule, pour injecter un matériau plastique moulable dans la cavité de moule afin de former une structure sur le substrat métallique.
PCT/US2016/055875 2016-10-07 2016-10-07 Moulage par injection à plusieurs entrées WO2018067164A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PCT/US2016/055875 WO2018067164A1 (fr) 2016-10-07 2016-10-07 Moulage par injection à plusieurs entrées

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/US2016/055875 WO2018067164A1 (fr) 2016-10-07 2016-10-07 Moulage par injection à plusieurs entrées

Publications (1)

Publication Number Publication Date
WO2018067164A1 true WO2018067164A1 (fr) 2018-04-12

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PCT/US2016/055875 WO2018067164A1 (fr) 2016-10-07 2016-10-07 Moulage par injection à plusieurs entrées

Country Status (1)

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WO (1) WO2018067164A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110014554A (zh) * 2019-05-23 2019-07-16 东莞市荣勤电子制品有限公司 一种包胶件注塑成型模具进胶结构
CN111452305A (zh) * 2020-05-29 2020-07-28 江苏华海诚科新材料股份有限公司 一种环氧模塑料大颗粒试验模具及其试验方法

Citations (3)

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Publication number Priority date Publication date Assignee Title
GB1506851A (en) * 1975-06-05 1978-04-12 Jesman L Shortening mobile aerials
RU95122163A (ru) * 1993-05-19 1997-11-27 Понт-А-Муссон С.А. Устройство для питания расплавленным металлом, в частности чугуном, установки для литья, и установка для литья металлических изделий, содержащая это устройство для питания
JP2001179786A (ja) * 1999-12-27 2001-07-03 Kanto Auto Works Ltd 多点ゲートを有する射出成形機

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Publication number Priority date Publication date Assignee Title
FR2705259B1 (fr) * 1993-05-19 1995-07-07 Pont A Mousson Dispositif d'alimentation en métal en fusion, notamment en fonte, d'une machine de coulée, et installation de coulée intégrant ce dispositif d'alimentation.

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1506851A (en) * 1975-06-05 1978-04-12 Jesman L Shortening mobile aerials
RU95122163A (ru) * 1993-05-19 1997-11-27 Понт-А-Муссон С.А. Устройство для питания расплавленным металлом, в частности чугуном, установки для литья, и установка для литья металлических изделий, содержащая это устройство для питания
JP2001179786A (ja) * 1999-12-27 2001-07-03 Kanto Auto Works Ltd 多点ゲートを有する射出成形機

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KAZMER DAVID O: "Razrabotka i konstruirovanie litievykh form", IZDATELSTVO PROFESSIYA, 2011, Sankt-Peterburg, pages 392 , 394 - 396 , 219-221, 225-228 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110014554A (zh) * 2019-05-23 2019-07-16 东莞市荣勤电子制品有限公司 一种包胶件注塑成型模具进胶结构
CN111452305A (zh) * 2020-05-29 2020-07-28 江苏华海诚科新材料股份有限公司 一种环氧模塑料大颗粒试验模具及其试验方法

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